Installation Instructions

Double Door System and Doors with an
Operating Sidelite

4/3/2010

Dorplex Industries Limited

Emidio Salvi 

 

Click here to download Installation Instructions Double Door with sidelites Document

Upon receipt of your Dorplex door system it is imperative that you unwrap and inspect it to ensure that it is free of manufacturers’ defects, not damaged and is as ordered.  Please take the time to measure to verify sizing.  It is best that this be conducted at time of delivery not at installation.  Any damages or deficiencies MUST be reported immediately and you are not to continue with installation.

Listed below are the steps necessary to properly install a door system.  It is not an all inclusive list and is recommended that it be uses as a guideline only.

  1. Preparation of rough opening

 

  • Make sure the opening in which the Dorplex door system is being installed is a minimum of 1” larger in width and ½” larger in height.  This will allow for adjustment when squaring and shimming the system in place.
  • Verify that the rough opening is plumb, square and level.
  • Clean and dry the sub floor area.

     

  1. Caulk the sub floor

 

  • Next ensure that the sill sub floor is solid and level and apply two or more beads of sealant.  This will reduce movement, lift and reduce the risk of water penetrating between the sub floor and the new Dorplex door system.  The rows of sealant should be about 1” apart and start about 1” from the inside edge.
  • In the event that there is a large gap between the sill and the sub floor it might be necessary for you to use low expansion foam.  This foam will help to insulate the system and will also assist in the reduction of movement.

 

 

  1. Door placement

 

  • Place the new door system into the opening with the door in the closed position.  If you are not a professional installer it is recommended that you do not try this alone.  You are to place the sill in the opening first and then tilt the door up into the opening.

 

 

  1. Plumb and fasten the door

  

  • Until the door unit has been properly secured into the rough opening, use extreme caution when opening the door panel.  The unit can be very heavy and may come loose from the rough opening.
  • Firmly place shims between the opening and the door system frame at the bottom (at sill) and at header in all four corners.  You may have to adjust the shims in order to get the door system square and level in place.  One way to ensure that the system is level and square is to close the door and visually inspect to see if the gap between the operating and fixed panel is consistent.  Please note you are to shim the fixed panel before you shim the operating side. 
  • Next shim behind each hinge at the jamb, on the fixed panel, bottom and top and then place shims on the opposite side of the frame behind the hinges on the operating panel.  This will allow you to adjust the gap around the door to reflect approximately 1/8” gap all around.
  • It is recommended that you place a 3” screw at each set of shims (total of 6 sets) through the frame.  Make sure all screws penetrate the shims and reach the stud to prevent the frame from warping.  On prefinished systems you can affix the screws behind the weather stripping so they are not visible.  In addition you can pre-drill 3 holes on the opposite side in which to install the installation screws.  In order to ensure the screws are not visible cover them with vinyl screw covers.
  • Only once you have confirmed that the door is plumb and level is it recommended that you drill the holes in the header and the sill for the flush bolt.  Slide the top flush bolt up against the header and bottom bolt down against the threshold to mark.  Mark where the bolts make contact and drill holes to receive the bolts.  The holes should be approximately 1 ½” deep.  Ensure that the flush bolts are fully engaged. If they are not then you may have to drill the holes deeper.  You will not be able to make any further adjustments to the fixed panel once the flush bolt holes have been drilled. 
  • When the shims are properly installed, there shouldn’t be any movement or twisting when the screws are tightened and counter-sunk.  Visually inspect to ensure the 1/8” gap has been maintained.  If there is any movement you will need to loosen the screws and shim tighter to maintain the gap and retighten the screws.
  • Test operation of the door system making sure that it performs properly.
  • You will be provided with six screws that you are required to install.  Placement of these screws is very important.  You must remove one of the center screws in each hinge and install the screws provided.  This will reduce the amount of sag or drift that may occur over time.  These screws must also penetrate the shims and reach the stud.
  • For door systems that have an operating side lite panel you will follow the same steps. 

 

 

  1. Finishing touches

  

  • Install dead bolt and striker plates at the correct location.
  • Insulate around the door between the jam and the wall studs.  Please note it is important to use  ONLY low expansion foam.  If you do not use low expansion foam then the door jamb will warp.
  • Caulk around the doorway including the front sill edge and along the exterior where it meets the brick or siding.
  • Adjust sweep, remove vinyl strip cover (slide cover toward the open side).  Push sweep down ward to make sure the fins make contact with the sill or until light is no longer visible.  Tighten screws and replace the vinyl strip cover.
  • Once installation is complete visibly inspect all joints to ensure the factory applied caulking has not cracked during installation.  If any cracks found the caulking should be reapplied to prevent water from entering the home.

Attached you will find a series of pictures that may assist in explaining the information provided above.